Textile fabric, use and production of a textile fabric and furniture element

ABSTRACT

A textile fabric ( 1 ) with elastic properties for use as upholstery material or for covering support or frame structures, for example, of seating furniture, furniture elements, ducts, automobile accessories or the like, comprising a woven, single-thread or multi-thread knitted or laid structure or composite textile material, for example, a nonwoven, as a self-supporting base material, wherein the base material has a total elongation to DIN 53360 under a tensile force of 25 N in at least one pulling direction of 0.1 to 10% and an irreversible elongation to DIN 53360 under a tensile force of 25 N in at least one pulling direction of less than 1%. According to the invention, it is provided that the base material has a pile ( 4 ) produced by flocking.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to a textile fabric for use as upholstery material or a covering for support or frame structures, for example, for seating furniture, furniture elements, ducts, automobile accessories, or the like, with a woven, single-thread or multi-thread knitted or laid structure or composite textile material, for example, a nonwoven material, as a self-supporting base material, whereby the base material has a total elongation according to DIN 53360 under a tensile force of 25 N in at least one pulling direction of 0.1 to 10%, preferably 0.5 to 6%, and even more preferably up to 4%, and an irreversible elongation according to DIN 53360 under a tensile force of 25 N in at least one pulling direction of less than 1%, preferably of less than 0.5%, and even more preferably of less than 0.1%, and especially preferably of less than 0.01%. Under a tensile force of 125 N, the total elongation according to DIN 53360 in at least one pulling direction can be 0.5 to 40%, in particular 1 to 30%, or even more particularly 5 to 22%, and the irreversible elongation according to DIN 53360 also under a tensile force of 125 N in at least one pulling direction can be less than 5%, in particular less than 3%, and even more particularly less than 2%.

Moreover, this invention relates to the use of a textile fabric of the above-mentioned type as an upholstery material or a covering for support or frame structures, for example, for seating furniture, furniture elements, ducts, or automobile accessories or the like, and a method for the production of a textile fabric with three-dimensional surface structures. Finally, this invention relates to a furniture element, in particular a seating furniture element, preferably a seatback and/or a seat portion, a decorative element, a duct, automobile accessories, or the like, having at least one textile fabric of the above-described type, in particular a textile cloth.

2. Description of Related Art

Elastic textile fabrics are known from the art, which fabrics are used, for example, in the furniture industry as upholstery or as coverings for support or frame structures, for example, for seating furniture or the like, and which in particular do not require padding or lining. For example, hose-like textile fabrics are used that are pulled over a suitable support or frame structure and are attached there. Such textile fabrics have a self-supporting base material, whereby the base material can be a woven, single-thread or multi-thread knitted or laid structure or composite textile material, for example, a nonwoven fabric.

High requirements are imposed on textile fabrics of the above-mentioned type. Thus, it is necessary that, after force-related stressing that accompanies an elongation or bulging of the fabric, the textile fabric returns again to its original shape to a certain extent based on its high return force. Thus, the textile fabric must have good extension recovery properties, which are induced or enhanced, in particular, by optionally present elastomer or rubber threads or fibers. A low total elongation under load as well as a very low irreversible elongation after decompression are prerequisites for the optical appearance of a support structure that is upholstered or covered with a fabric of the kind in question or of a frame structure that is upholstered or covered with a fabric of the kind in question also to be sufficient to meet high quality requirements in the case of repeated stress or use.

From German Utility Model DE 20 2007 014 733 U1 and corresponding U.S. Pat. No. 7,851,390 B2, a textile fabric for the production of an upholstery or a covering that has heat-shrinking properties is known. Under the effect of heat, a lengthwise reduction of at least one heat-shrinkable plastic yarn of the known fabric results, so that the fabric can have a lower preliminary stress in the initial state before upholstering or covering is performed. The necessary inherent stress of the upholstery or covering applied on the support structure or the frame is only produced by the shrinking process of the surface material. The inherent stress achieved by the heat-shrinking process ensures high loading capacity and upholstery or covering that is largely free of wrinkles, without worrying about deviations in measurement or quality by excessive elongation or by bulging of the textile fabric when upholstering or covering the support or frame structure. In particular, a wrinkle-free upholstery or a wrinkle-free covering for the support or frame construction, for example, for room structures such as chairs or the like, is ensured in a simple way even in the case of low preliminary stress forces of the surface material.

In order to produce three-dimensional textile surface structures in the base material of a textile fabric of the kind in question and to provide a certain appearance or design to the textile fabric, the use of flocked yarns as warp thread and/or weft thread in the production of such textile fabrics is known from the state of the art. By using flocked yarns for the production of fabrics, it is ensured that the elongation properties and the shape recovery behavior of the fabric does not change or changes only insignificantly in comparison to a fabric produced with use of unflocked yarns. The higher configuration freedom of the design or the outer appearance of the three-dimensional surface structures produced with use of flocked yarns is limited, however, by the yarn thickness and in the case of woven textile fabrics by the number of warp or weft threads.

SUMMARY OF THE INVENTION

The object of this invention is to provide, in a simple way and economically, a textile fabric with a three-dimensional surface structure on at least one flat side of the fabric and a production method for the production of such a fabric as well as a furniture element of the above-mentioned type, whereby the configuration of the three-dimensional surface structure with a higher configuration freedom is possible and the surface structure is distinguished by very fine and delicate textile structures, and whereby the shape recovery behavior of the fabric is very good.

Surprisingly enough, in connection with the invention, it has been found that the above-mentioned formulation of the object is achieved in a suitable way when the base material of a textile fabric of the above-mentioned kind is flocked at least in places. As a three-dimensional surface or textile structure, the nap that is produced by flocking can be provided with at least one flat side or outside of the textile fabric according to the invention, whereby preferably a cloth is flocked as base material. In principle, in the same way, however, a knitted fabric, such as, for example, a single-thread knitted fabric or a multi-thread knitted fabric, can also be flocked. Also, non-woven textile fabrics, such as thread composites or non-woven fabrics, can be flocked. In all of the above-mentioned cases, three-dimensional surface structures or textile structures are produced from flock fibers, whereby depending on length and fineness of the flock fibers with respect to optics and surface feel, very appealing textile fabrics with three-dimensional surface structure can be provided. Based on the high level of fineness of the surface structures that are produced, which can be obtained by flocking, any patterns can be depicted with high resolution. If a cloth is flocked as base material, the fine structure of the surface topography of the fabric according to the invention that can be obtained by flocking is in particular not linked to the number of warp threads or weft threads. In principle, the flocking in this connection offers the advantage of being able to freely form the design of the nap layer as in the case of a pushing process.

In connection with the invention, surprisingly enough, it could further be noted that by suitable configuration of the flocking, the irreversible elongation of the textile fabric according to the invention is increased relative to the same fabric with unflocked base material only by less than 10%, preferably by less than 5%, and in particular by less than 1%. Preferably, the total elongation and/or the irreversible elongation of the flocked base material corresponds essentially to the total elongation or irreversible elongation of the same unflocked base material. In connection with the invention, the surprising finding could be obtained that a flocking of the base material, contrary to the opinion of experts, does not result in a relevant worsening of the elongation properties, and in particular, of the shape recovery behavior of the surface material, if the flocking is performed in a suitable way. In connection with the invention, extensive tests have shown that despite the flocking of the base material, a force-related stressing of the base material is not associated with a bulging of the surface material after withdrawal of force.

According to the invention, the flocking method is designed in such a way that the nap associated with the base material does not counteract the return forces of the base material in the case of withdrawal after a force-related stressing and the return forces are not or are only insignificantly reduced. This can be achieved by a suitable selection of the nap fibers that consist of specific fiber materials, by a specific nap fiber length and thickness, as well as by the adhesive that is used and the amount of adhesive.

For the flocking, the methods known in textile engineering are used. Electrostatic flocking is preferred since, with the latter, for example, a nap can be produced from fibers perpendicular to the base material in the adhesive film by the orientation of the flock fibers along the field lines in the electrostatic field, by which a velvety nature of the flocked product is achieved. In addition, the methods of the mechanical and pneumatic flocking can also be used for the production of the textile fabrics according to the invention.

To form the fiber nap, cut short fibers according to the invention are especially preferred. The flock fibers can have a length of 0.5 to 3 mm. The titers of the flock fibers are preferably below 10 dtex, even more preferably below 7 dtex. The fiber length must be matched to the titer since the degree of slimness of the fibers decisively influences their processibility in the flocking as well as the usage properties of the flocked base material. Degree of slimness is defined as the ratio of the mean fiber length to the mean fiber thickness.

Cut short fibers for flocking are usually produced from chemical fiber optic cables. For the textile fabrics according to the invention, for example, aliphatic polyamide fibers, such as, for example, polyamide 6 or polyamide 6.6, are especially preferred for forming fluorine. Also, short fibers that are made of polyester or polyacrylonitrile as well as other suitable polymers can be used.

As adhesives for the flocking, products of different chemical composition can be used. Thus, polyvinyl acetate and its copolymers, polyacrylic acid ester and its copolymers, polyurethanes, styrene-copolymers and styrene-terpolymers, polyvinyl chloride as well as vinyl choride-vinylidene mixed polymerizates can be used. These adhesives are present either as solvent-containing systems or as solvent-free aqueous dispersions. For the flocking, adhesives according to the invention that are based on polyacrylic acids or their copolymers have proven especially suitable. Good results can also be achieved with adhesives based on polyurethane.

The base material of the fabric according to the invention is, in particular, a textile surface material, as it is already described in German Utility Model DE 20 2007 014 733 U1 and corresponding U.S. Pat. No. 7,851,390 B2. The disclosure of German Utility Model DE 20 2007 014 733 U1 and corresponding U.S. Pat. No. 7,851,390 B2 is hereby incorporated by reference, in particular with respect to the composition and the properties of the textile base material.

The base material is preferably designed as a cloth with a number of elastic threads or fibers, which can be present as monofils or multifils, in the weft direction and with a number of elastic threads or fibers, also as monofils or multifils, in the warp direction, whereby in the weft direction and/or in the warp direction, the cloth is designed in an elastic and reversibly elongatable manner, and whereby the total elongation in the weft direction according to DIN 53360 is approximately 1 to 10%, preferably 2 to 8%, and even more preferably 4 to 6%, under a tensile force of 25 N, and the irreversible elongation in the weft direction according to DIN 53360 is less than 1.0%, preferably less than 0.5%, and in particular less than 0.1% under a tensile force of 25 N, and/or whereby the total elongation in the warp direction according to DIN 53360 is approximately 0.1 to 5%, preferably 0.5 to 3%, and even more preferably 1 to 2% under a tensile force of 25 N, and the irreversible elongation in the warp direction according to DIN 53360 is less than 0.5%, preferably less than 0.1%, under a tensile force of 25 N. The total elongation in the weft direction according to DIN 53360 under a tensile force of 125 N can, however, be 10 to 40%, preferably 20 to 30%, and even more preferably less than 25%, and the irreversible elongation in the weft direction according to DIN 53360 can be less than 5%, preferably less than 3%, and even more preferably less than 2% under a tensile force of 125 N, and/or the total elongation in the warp direction according to DIN 53360 can be 1 to 10%, preferably 2 to 8%, and even more preferably 4 to 6% under a tensile force of 125 N, and the irreversible elongation in the warp direction according to DIN 53360 can be less than 1.0%, and preferably less than 0.5%, under a tensile force of 125 N. The above-mentioned values were determined with a universal testing machine with the designation Zwick 1455 having a clamping length of 200 mm, a measuring length of 100 mm, and a sample width of 50 mm under normal climate conditions according to DIN EN ISO 139, whereby the thickness of the flocking on the sample exhibited no variations.

Such a cloth is distinguished by self-supporting properties, sufficient elasticity, and a good shape recovery behavior after withdrawal of force and is especially suitable for use as upholstery material or a covering for support or frame structures of furniture elements.

In an especially preferred embodiment of the invention, the base material is designed as cloth with a number of monofilaments in the weft direction and/or with a number of monofilaments in the warp direction, whereby the diameter of the monofilaments in the weft direction and/or in the warp direction of a woven base material can be even more preferably between 0.05 and 1.0 mm, and especially preferably between 0.1 and 0.4 mm. In particular, the support cloth can consist of elastic monofilaments in the warp and weft directions, which preferably can have a diameter of approximately 0.2 mm. Also, the cloth can consist of non-elastic monofilaments and/or can have such.

If the base material is designed as cloth, between 8 and 30 weft threads or weft fibers per cm, preferably between 10 and 20 per cm, even more preferably between 12 and 14 per cm, and/or between 8 and 30 warp threads or warp fibers per cm, preferably between 10 and 20 per cm, and even more preferably between 14 and 16 per cm, can be provided. For example, the base material can have 15.5 warp threads per cm and a weft density of 13.5 weft/cm. The base material of the fabric according to the invention is consequently tightly woven, which simplifies the flocking of the base material and ensures a very appealing surface feel and optics of the formed nap.

The base material can be transparent at least in some areas, and if it is designed as a cloth, it can have transparent threads or fibers in the weft direction and/or in the warp direction. Preferably, a support cloth consists of transparent monofilaments. The transparency of a support cloth can also be achieved in that the cloth, although tightly woven, has a net-like structure when using monofilaments. In the case of colored monofilaments, the network nature also causes the support cloth to appear transparent. As a result, it is possible, at least in some areas, to see the area covered or upholstered with the fabric according to the invention through the base material.

In particular, in connection with the use of transparent threads or fibers, it can be provided that the base material is flocked only in some areas. As a result, on the same side of the fabric, areas of the base material that are flocked and unflocked are provided lying beside one another, whereby the unflocked areas are preferably transparent and allow the area below the base material to show through. As a result, an especially appealing appearance of the fabric according to the invention can be achieved. In the flocking of the base material, in some areas, according to the invention, almost any patterns as three-dimensional surface structures can be provided and unflocked transparent areas of the base material can be present in addition. The surface design, in this case, can be almost freely configured as in the case of a pushing process.

In particular, it is provided that the flocked areas extend in a strip-like manner either in the warp direction or in the weft direction, whereby the flocked areas are separated from one another by unflocked areas of the base material. Preferably, coherent unflocked areas extend between the flocked areas over the entire length or width of the fabric according to the invention. As a result, it is ensured that the shape recovery behavior of the fabric according to the invention does not change or changes only negligibly at least in a pulling direction by the flocking.

In order to achieve a high strength connection of the nap to the base material, it can be provided that the nap extends from a top side of the base material through the base material to the bottom side of the base material and forms a coherent nap layer, at least in some areas on the bottom side of the base material. In this connection, the top side of the base material is not closed, but rather has gaps, through which the flock fibers penetrate the base material and can form a nap on the bottom side of the material. In the case of woven base materials, in particular in the case of a net-like support cloth made of monofilaments, the base material can be woven in such a way that the flock fibers can penetrate the support cloth in the flocking. The textile fabric according to the invention then has surface areas flocked on both surface sides that are connected to one another over the thickness of the base material.

In order to make the flocking of the base material with high quality possible, the base material can have slide resistance, in particular, in each case, relative to the warp direction or the weft direction and according to DIN 53868, of at least 50 N, in particular at least 100 N, preferably at least 150 N, preferably at least 200 N, and especially preferably at least 300 N. The tensile strength of the base material, in particular in each case relative to the warp direction and/or the weft direction and according to EN ISO 13934-1, can be at least 300 N, in particular at least 400 N, preferably at least 600 N, and preferably at least 800 N. Otherwise, the propagation tearing resistance of the base material according to EN ISO 13937-3, in particular relative to the weft direction, can be at least 30 N, in particular at least 40 N, preferably at least 60 N, and preferably at least 80 N. This means that all above-mentioned values of the mechanical properties of the base material do not absolutely have to be provided in combination with one another.

All of the above indications of values and the indicated intervals in each case encompass all intermediate values, i.e., not only the lower limits or, in the case of intervals, the interval limits, without the latter requiring express reference. The above-mentioned features can be combined with one another in any way desired.

In particular, there are a number of possibilities for configuring and further developing the textile fabric according to the invention as will become apparent from the subsequent detailed description of a preferred embodiment of the invention with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view of a fabric according to the invention, and

FIG. 2 shows the fabric depicted in FIG. 1 from below.

DETAILED DESCRIPTION OF THE INVENTION

In FIGS. 1 and 2, a textile fabric 1 according to the invention is depicted with elastic properties for use as upholstery material or covering for support or frame structures, for example, for seating furniture, furniture elements, ducts, automobile accessories, or the like. The fabric 1 has a base material designed as cloth, which is self-supporting and is formed by a number of elastic monofilaments 2 in the warp direction and elastic monofilaments 3 in the weft direction. The fabric 1 thus has a net-like structure. FIG. 1 shows the fabric 1 in a top view, while FIG. 2 shows the same fabric 1 in a view from below. It is understood that in FIGS. 1 and 2, a partial area of the fabric 1 is depicted only diagrammatically.

The monofilaments 2, 3 can have a diameter of approximately 0.1 to 0.3 mm, preferably 0.2 mm. Instead of monofilaments 2, 3, elastic multifilaments can also be used for the production of base material. The elasticity of the base material is in this case controlled in such a way that the fabric 1, for example, ensures a high degree of seat comfort in the covering for frame structures of a piece of seating furniture, and that the cloth returns again into the starting position after use.

The cloth of the base material preferably made of polyester fibers. The total elongation of the base material according to DIN 53360 under a tensile force of 25 N in the warp direction can be 0.5 to 5%, preferably approximately 1%, and in the case of an irreversible elongation of less than 1%, preferably ±0.0%. The total elongation according to DIN 53360 can be approximately 1 to 10%, preferably approximately 4%, under a tensile force of 25 N in the weft direction, also in the case of an irreversible elongation of less than 1%, preferably ±0.0%. The total elongation according to DIN 53360 of the base material under a tensile force of 125 N can be between 4 and 6%, preferably approximately 5%, in the warp direction, while the irreversible elongation in the warp direction under a tensile force of 125 N can also preferably be less than 1.0%, in particular ±0.0%. The total elongation of the base material under a tensile force of 125 N in the weft direction can be between 20 and 30%, preferably approximately 23%, whereby the irreversible elongation in the weft direction is preferably less than 5%, in particular approximately 1.5%. In principle, the base material can also have elongation values, which deviate by preferably less than 50%, preferably less than 20%, from the above-mentioned elongation values. As a result, self-supporting properties of the base material are achieved, which ensure the suitability of the base material in particular as a wrinkle-free covering for frame structures for chairs or the like, whereby the textile fabric 1 has high reversible elongation properties and a high carrying capacity.

As is seen from FIGS. 1 and 2, the base material in some areas has a nap 4 that is produced by flocking. As flock fibers, polyamide fibers can preferably be used. The flocked areas of the base material extend in the warp direction in a strip-like manner. Between the flocked areas, unflocked areas 5 are provided, which separate the flocked areas from one another in the weft direction and which preferably extend in the warp direction over the entire length of the fabric 1. It is just as possible that the flocked areas extend in the weft direction and are separated from one another in the warp direction by unflocked areas, whereby unflocked areas can be provided that extend in the weft direction over the entire width of the fabric 1. As a result, the flocking of the base material proceeds in such a way that, because of the nap 4, only a negligible change in the elongation properties, in particular irreversible elongation, occurs. Further, a flocking of the base material is provided in such a way that the irreversible elongation of the flocked base material relative to the same unflocked base material is increased by less than 10%, preferably by less than 5%, and in particular by less than 1%. Thus, three-dimensional surfaces are produced by flocking, without the shape recovery properties necessary for the suitability of the fabric 1 as an upholstery material or covering material or reversible elongation properties of the base material being impaired.

In the depicted embodiment, the base material has 15.5 monofilaments 2 in the warp direction per cm and 13.5 monofilaments 3 in the weft direction per cm. It is also understood that another warp density and/or weft density can be provided. Between the monofilaments 2, 3, gaps 6 are present, so that the flock fibers in the case of flocking of the base material from above penetrate through the cloth and also coherent flocked areas can form on the bottom side of the fabric 1, which is depicted in FIG. 2. As a result, a high level of strength of the flocking is ensured. Moreover, the shape recovery behavior of the fabric 1 is improved.

The monofilaments 2, 3 are preferably transparent, so that it is possible to see through the unflocked areas 5. A transparent appearance of the fabric 1 is also achieved by the network nature of the fabric 1 with use of monofilaments 2, 3, so that in principle, it is also so that the fabric 1 appears transparent with use of colored monofilaments 2, 3. The depicted fabric 1 thus is distinguished by an aesthetically pleasing design with three-dimensional surface structures produced by flocking, whereby the configuration of the design is not linked to the number of monofilaments 2, 3 in the warp direction or the weft direction, and it can be freely configured as a pushing process. 

What is claimed is: 1-12. (canceled)
 13. Textile fabric with elastic properties for use as upholstery material or a covering for support or frame structures, comprising: a cloth as a self-supporting base material with a plurality of elastic threads or fibers extending in weft and with warp directions, whereby the cloth is elastic and reversibly elongatable manner in the weft and warp directions such that the total elongation in the weft direction according to DIN 53360 is 1 to 10% under a tensile force of 25 N, and the irreversible elongation in the weft direction according to DIN 53360 is less than 0.5% under a tensile force of 25 N, or the total elongation in the warp direction according to DIN 53360 is 0.1 to 5% under a tensile force of 25 N, and the irreversible elongation in the warp direction according to DIN 53360 is less than 0.5% under a tensile force of 25 N, and wherein the base material has a nap that has produced by one of electrostatic, mechanical or pneumatic flocking with flock fibers.
 14. Textile fabric according to claim 13, wherein the flocking of the base material is provided in such a way that the irreversible elongation of the base material relative to the same base material without said flocking is increased by less than 10%.
 15. Textile fabric according to claim 13, wherein the total elongation in the weft direction according to DIN 53360 is 2 to 8% under a tensile force of 25 N, and the irreversible elongation in the weft direction according to DIN 53360 is less than 0.1%, under a tensile force of 25 N.
 16. Textile fabric according to claim 13, wherein the total elongation in the warp direction according to DIN 53360 is 0.5 to 3% under a tensile force of 25 N, and the irreversible elongation in the warp direction according to DIN 53360 is less than 0.1% under a tensile force of 25 N.
 17. Textile fabric according to claim 13, wherein the monofilaments in at least one of the weft direction and the warp direction have a diameter between 0.05 and 1.0 mm.
 18. Textile fabric according to claim 17, wherein between 8 and 30 weft threads or fibers are provided per cm.
 19. Textile fabric according to claim 17, wherein between 14 and 16 weft threads or fibers per cm are provided.
 20. Textile fabric according to claims 13, wherein the base material has at least one of a slide resistance relative to the warp direction or the weft direction according to DIN 53868 of at least 50 N, a tensile strength relative to at least one of the warp and weft directions according to EN ISO 13934-1 of at least 300 N, and a propagation tearing resistance relative to the weft direction according to EN ISO 13937-3 of at least 30 N.
 21. Textile fabric according to claim 13, wherein the base material is transparent in at least some areas.
 22. Textile fabric according to claim 13, wherein the base material is flocked only in some areas.
 23. Textile fabric according to claim 13, wherein the nap extends from a top side of the base material through the base material to a bottom side of the base material, and at least in some areas, forms a coherent nap layer on the bottom side of the base material.
 24. Method for the production of a textile fabric having three-dimensional textile structures and elastic properties for use as upholstery material or a covering for support or frame structures, comprising the steps of: providing a cloth as a self-supporting base material that has a plurality of elastic threads or fibers in weft and warp directions, and flocking the base material with flock fibers in at least in some areas by one of an electrostatic, mechanical and pneumatic manner to produce a three-dimensional textile structure having an elastic and reversibly elongatable manner in at least one of the weft direction and the warp direction and whereby the cloth is elastic and reversibly elongatable manner in the weft and warp directions such that the total elongation in the weft direction according to DIN 53360 is 1 to 10% under a tensile force of 25 N, and the irreversible elongation in the weft direction according to DIN 53360 is less than 0.5% under a tensile force of 25 N, or the total elongation in the warp direction according to DIN 53360 is 0.1 to 5% under a tensile force of 25 N, and the irreversible elongation in the warp direction according to DIN 53360 is less than 0.5% under a tensile force of 25 N.
 25. Furniture element having at least one textile fabric according to claim
 13. 